UNWEgSfTI I OK HUSSOH c m mmayssa
Transcript of UNWEgSfTI I OK HUSSOH c m mmayssa
U N W E g S f T I I OK H U S S O H c m m m a y s s a
UTHM
*300000021fi1574*
UNIVERSITI TUN HUSSEIN ONN MALAYSIA
BORANG PENGESAHAN STATUS TESIS*
JUDUL: THREE PHASE INDUCTION MOTOR INVERTER APPLICATION FOR MOTION CONTROL
SESIPENGAJIAN: 2007/2008
Saya M O H D RUSMI BIN ABDUL GHANI (HURUF BESAR)
mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah)* ini di simpan di Perpustakaan dengan syarat-syarat kegunaan seperti berikut:
1. Tesis adalah hakmilik Universiti Tun Hussein Onn Malaysia. 2. Perpustakaan dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi
pengajian tinggi. 4. ** Sila tandakan (V)
• • • SULIT (Mengandungi maklumat yang berdarjah keselamatan atau
kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972)
TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)
TIDAK TERHAD
Disahkan oleh:
(TANDATANGAN PENULIS)
Alamat Tetap:
A925.KG.HULU TAKJR, SEBERANG TAKIR, 21300 KUALA TERENGGANU. TERENGGANU
TARIKH: APRIL 2008
(TANDATANGAN PENYELIA)
P.MADYA DR. ZAINAL ALAM BIN HARON
TARIKH: 2 - ^ A P R I L 2008
CATATAN: * Potong yang tidak berkenaan. ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak
berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan dikelaskan sebagai SULIT atau TERHAD.
• Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertai bagi pengajian secara kerja kursus dan penyelidikan atau Laporan Projek Sarjana Muda (PSM).
"I hereby declare that I have read this thesis and in my opinion this thesis is sufficient in
term of scope and quality for the award of the degree of
Master of Electrical Engineering ".
Signature
Name of Supervisor : P.Madya DR. ZAINAL ALAM BIN HARON
Date APRIL 2008
THREE PHASE INDUCTION MOTOR INVERTER APPLICATION FOR
MOTION CONTROL
MOHD RUSMI BIN ABDUL GHANI
A project report submitted in partial
fulfillment of the requirement for the award of the
Degree of Master of Electrical Engineering
Faculty of Electrical and Electronic Engineering
Universiti Tun Hussein Onn Malaysia
APRIL 2008
ii
I declare that this report on "Three Phase Induction Motor Inverter Application for
Motion Control" is the result of my own project except for works which have been cited
in the references. The report has not been accepted any degree and not concurrently
submitted in candidature of any other degree.
Signature
Name of Author : MOHD RUSMI BIN ABDUL GHANI
Date : APRIL 2008
For my dearest wife Salina,
My beloved daughters NurAfifah Nabilah and NurAisyah Najihah,
My beloved sons M.Aqil Hanis and M.aiman Hakimi
&
My family for their encouragement and blessing
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ACKNOWLEDGMENT
In the name of Allah, the most Gracious and most Compassionate
First of all, I am greatly indebted to Allah SWT on His blessing to make this
project successful.
I would like to express my gratitude to honourable Prof. Madya Dr. Zainal Alam
bin Haron, my project supervisor for his guidance and help rendered throughout this
project.
Special thank and appreciation goes to all my friends, technicians and others
whose name could not be mentioned here one by one. Your encouragement, help and
concern is greatly appreciated.
My warmest thanks go to my parent and parent-in-law for their support. My
highest appreciation goes to my loving wife, Salina Salleh and my beloved daughters
Nur Afifah Nabilah, Nur Aisyah Najihah, my beloved sons M.Aqil Hanis and M.Aiman
Hakimi for their unconditional support and love that continuously fed my strength desire
to succeed.
Finally, I wish to thank everyone who has helped in one way or another towards
the successful implementation of this project.
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ABSTRACT
The aim of this project is to become familiar with the operation and use of the
Toshiba VFFS1 Inverter to reduce motor starting current and also to improve on the
quality of the motion executed motor-driven equipment. Various methods exist to
reduce the high starting currents of three phase induction motors. A low starting current
not only reduces stresses on the power utility but also decreases stresses on the motor
and the driven equipment. As designed, inverters can reduce the starting current,
especially by programming the motion to follow a trapezoidal or s-curve profile. A
trapezoidal motion profile reduces jerky motion while the s-curve profile totally
eliminates it. The challenge in motion control is always how to achieve precise motion
with minimum jerk, and overshoot in position as well as velocity. There are four
methods that can be used to connect the inverter to a motor, namely, by control panel,
using a controller computer, remote terminal box, or a PLC. A number of induction
motors were tried with the inverter to observe their response to the different motion
profiles programmed into the inverter. The results are reported and discussed in this
work.
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ABSTRAK
Matlamat projek ini ialah untuk menyesuaikan dan menggunakan operasi
penyongsang Toshiba VFFS1 untuk mengurangkan arus permulaan motor dan juga
melakukan pembaikan gerakan peralatan pacuan motor. Terdapat pelbagai kaedah yang
digunakan untuk mengurangkan arus permulaan yang tinggi bagi motor aruhan tiga fasa.
Arus permulaan yang rendah bukan saja dapat mengurangkan tekanan pada peralatan
kuasa, ia juga dapat mengurangkan tekanan pada motor dan pemacu. Penyongsang
direka bagi mengurangkan arus permulaan, terutama oleh pengatucaraan gerakan untuk
mengikut profil trapezoid atau lengkuk-s. Satu profil gerakan trapezoid mengurangkan
gerakan sentakan dan lengkuk-s dapat menghilangkan sepenuhnya sentakan. Cabaran
dalam kawalan gerakan adalah untuk mencapai gerakan yang lancar dengan sentakan
minima dan dalam kedudukan terlajak serta halaju. Terdapat empat kaedah yang boleh
digunakan untuk menyambung penyongsang ke sebuah motor, iaitu, oleh panel kawalan,
menggunakan sebuah komputer pengawal, kotak pangkalan jauh, atau satu PLC.
Sejumlah motor aruhan telah dicuba dengan penyongsang untuk memantau kawalan
gerakan penyongsang yang berbeza arahan. Hasilnya telah diapor dan dibincangkan
dalam keija ini.
TABLE OF CONTENTS
CHAPTER CONTENTS PAGE
THESIS STATUS CONFIRMATION
SUPERVISOR'S CONFIRMATION
TITLE
TESTIMONY
DEDICATION
ACKNOWLEDGEMENT
ABSTRACT
ABSTRAK
TABLE OF CONTENTS
LIST OF FIGURES
LIST OF TABLES
LIST OF SYMBOLS / ABBREVIATIONS
LIST OF APPENDIXES
CHAPTER 1 INTRODUCTION 1
1.1 Starting of Induction Motor 1
1.2 Type of Starter Motor 2
1.2.1 D.O.L Starter 2
1.2.2 Star/Delta Starter 2
1.2.3 Soft Starter 3
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ii
iii
iv
v
vi
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xi
xiv
XV
xviii
1.2.4 Inverter 3
1.3 Background of the Study 4
1.4 Problem statement 6
1.5 Aim of the study 6
1.6 Objectives of the study 7
1.7 Research Scopes 7
1.8 Report Outline 8
CHAPTER II LITERATURE REVIEW 9
2.1 Motion Control 9
2.2 Elements of Motion Control 10
2.2.1 Position Control 10
2.2.2 Velocity Control 10
2.2.3 Acceleration/Deceleration Control 11
2.2.4 Torque Control 12
2.2.5 Jerk 12
2.2.6 Trapezoid and S-Curve 13
2.3 Basic Theory of Inverters 15
2.3.1 Voltage Source Inverter 15
2.3.2 The Three-Phase Bridge VSI 16
2.3.3 Current Source Inverter 17
2.3.4 The Three-Phase Current Source
Bridge Inverter 17
2.4 Speed Control of Induction Motors 18
2.4.1 Speed Control by Changing the Line
Frequency 19
2.4.2 Speed Control by Pole Changing 22
2.5 The Frequency Converter 23
2.5.1 The Rectifier 25
2.5.2 Full-wave Controlled Rectifier 26
2.5.3 The Intermediate Circuit 28
2.5.4 The Inverter 31
2.5.5 Transistor 34
2.5.6 Pulse Width Modulation PWM 36
Review of Important Research Works on 40
Motion Control
CHAPTER III METHODOLOGY 43
3.1 Research Flow 43
3.2 Toshiba VF-FSI Instructions Manual 45
3.3 Simplified Operation of the VF-FS1 Inverter 45
3.3.1 Local Mode and Remote Mode 46
3.3.2 How to Start and Stop 47
3.3.3 Start and Stop using the Operation
Panel Keys (CNOD=l) 48
3.3.4 RUN/STOP of an External Signal
to the Terminal Board (CNOD = 0) 48
3.3.5 Coast Stop 48
3.3.6 How to set the Frequency 49
3.3.7 Setting the Frequency using the
Operation Panel (FNOD=3) 50
3.4 How to Operate the VF-FS 1 50
3.5 Setting Program for Inverter 51
3.5.1 Setting the Controller Computer
to Panel Inverter 52
3.5.2 Setting Remote Terminal Box to
Panel Inverter 53
3.5.3 Setting Controller Computer to
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PLC and to Panel Inverter 54
3.6 Setting CX-Program for PLC 56
3.7 Serial Communication 58
3.8 Setting the Controller Computer 58
3.8.1 Parameters Listed in the Table 61
3.8.2 Parameter Setting, Import, and
Export are Executed 62
3.8.3 Monitoring Display 63
3.8.4 Open/Save as 68
3.9 Setting Acceleration/Deceleration Time 69
3.9.1 Automatic Acceleration/Deceleration70
3.9.2 Manually Setting
Acceleration/Deceleration Time 72
3.9.3 Acceleration/Deceleration Time 2 73
3.9.3.1 Linear Acceleration /
Deceleration 73
3.9.3.2 S-pattern Acceleration /
Deceleration 1 74
3.9.3.3 S-pattern Acceleration /
Deceleration 2 74
3.9.4 Switching Acceleration /
Deceleration Time 1 and 2 75
3.9.4.1 Selection using Parameters 76
3.9.4.2 Switching by Frequencies 76
3.10 Testing Implementation 77
3.10.1 Puma Compressor 78
3.10.2 Crusher Machine 79
3.10.3 Circular Machine 80
3.10.4 Other Motor Testing 81
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CHAPTER TV RESULTS AND DISCUSSIONS 82
4.1 Result of Puma Compressor
4.2 Result of Crusher machine
4.3 Result of Circular machine
4.4 Results for Other Motor Testing
83
87
90
94
CHAPTER V CONCLUSIONS 95
REFERENCES 97
APPENDIXES 100
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LIST OF FIGURES
FIGURE TITLE PAGE
2.1 Trapezoidal model (a) and S-Curve model (b) 13
2.2 Comparison of Trapezoidal and S-Curve Velocity
Profiles 14
2.3 A Three-Phase Inverter 16
2.4 Circuit Diagram Three-Phase CSI 18
2.5 Variable-frequency speed control in an induction
motor 21
2.6 The method of change an a.c. motor speed 24
2.7 Simplified diagram of a frequency converter 25
2.8 Single and three-phase a.c. voltage 26
2.9 The mode of operation of the thyristor 27
2.10 The full wave controlled rectifier 27
2.11 Variable d.c. intermediate circuit 28
2.12 Constant or variable voltage intermediate circuit 29
2.13 Variable voltage intermediate circuit 29
2.14 The chopper transistors varies the intermediate
circuit voltage 30
2.15 Inverter for variable intermediate circuit current 3 2
2.16 Inverter for variable or constant intermediate
circuit voltage 33
2.17 Modulation of pulse amplitude or width 34
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2.18 How the switching frequency affects the motor
current 35
2.19 The principle of the sine-controlled P WM 3 7
2.20 The output voltage at PWM 38
2.21 The output voltage can be increased by utilizing
the third harmonic 40
3.1 Flowchart of research work 44
3.2 The coast stop 49
3.3 Process the setting mode 51
3.4 Connection to setting controller computer to
inverter 52
3.5 Connection to setting the remote terminal box
to panel inverter 54
3.6 Connection from PLC port A to control circuit
terminal board 55
3.7 Connection controller computer to PLC and to
panel inverter 56
3.8 Ladder diagram circuit for forward and reverse
control 57
3.9 Starting of PCM001Z displays. 59
3.10 The main menu and Parameter Table 5 9
3.11 The setup of the RS-232C 60
3.12 The parameter setting value 62
3.13 (a): Monitoring display tab page screen 63
(b): monitor setting tab page screen 64
3.14 Monitor - Data display screen 65
3.15 Se tAUl to 1 or 2. 70
3.16 Manually setting AU1 = 0. 72
3.17 Linear acceleration/deceleration 73
3.18 S-pattern acceleration/deceleration 1 74
3.19 S-pattern acceleration/deceleration 2 75
X I V
3.20 Selection using parameters 76
3.21 Switching by frequencies 77
3.22 The puma compressor 78
3.23 The crusher machine 79
3.24 The circular machine 80
4.1 The waveform when setting AU1=1 84
4.2 The waveform when setting AU1=0 85
4.3 The comparison between AU1=1 and AU1=0 86
4.4 The waveform when setting AU1=1 88
4.5 The waveform when setting AU1=0 89
4.6 The comparison between AU1=1 and AU1=0 90
4.7 The waveform when setting AU1=1 91
4.8 The waveform when setting AU1=0 92
4.9 The comparison between AU1=1 and AU1=0 93
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LIST OF TABLES
TABLE TITLE PAGE
3.1 Step to Start and Stop the Inverter 47
3.2 Remote Mode Selection 47
3.3 FNOD Setting Procedure 49
3.4 Listed of Parameters 61
3.5 Conditions on Baud Rate 66
3.6 Parameter Setting 71
3.7 Methods of Setting Automatic Acceleration /
Deceleration 71
3.8 Selecting an Acceleration / Deceleration Pattern 73
4.1 Comparisons Testing with Inverter and without
Inverter for Puma Compressor 86
4.2 Comparisons Testing with Inverter and without
Inverter for Crusher Machine 89
4.3 Comparisons Testing with Inverter and without
Inverter for Circular Machine 93
LIST OF SYMBOLS/ ABBREVIATIONS
Symbols:
M
n
/ Tt
<f>
CO
9
s
C
k
L
m
M
T
N
P
P
V
t
Micro (106)
Ohm
Frequency (Hz)
Pi (180)
Flux
Omega
Phase displacement
Slip
Capacitance
kilo (103)
Inductor
mili (10"3)
Mega (106)
Switching period
Speed
Pole
Power
Voltage
Time
Abbreviations:
AC (a.c) - Alternating Current
DC (d.c) - Direct Current
e.m.f - Electric Magnetic Force
THD - Total Harmonic Distortion
UPS - Uninterruptible Power Supply
CVCF - Constant Voltage and Constant Frequency
KV - Kilo-Volt
BJT - Bipolar Junction Transistor
TTL - Transistor-transistor Logic
MOS - Metal Oxide Semiconductor
CMOS - Complementary Metal Oxide Semiconductor
IGBT - Insulated Gate Bipolar Transistor
MOSFET - Metal Oxide Semiconductor Field Effect Transistor
PWM - Pulse Width Modulation
IEEE - Electrical and Electronic Engineer
VSI - Voltage Source Inverter
CSI - Current Source Inverter
RCL - Rotor Core Losses
AG - Air Gap
sync - Synchronous
ACC - Acceleration
DEC - Deceleration
LIST OF APPENDIXES
APPENDIX ITEM PAGE
A SPECIFICATION, DATA FOR TOSHIBA
INVERTER 100
B PERMISSION LETTER 107
C DATA, SPECIFICATION AND THE WAVEFORMS
TESTING BY PUMA COMPRESSOR 110
D DATA, SPECIFICATION AND THE WAVEFORMS
TESTING BY CRUSHER MACHINES 113
E DATA, SPECIFICATION AND THE WAVEFORMS
TESTING BY CIRCULAR MACHINES 116
F DATA, SPECIFICATION AND THE WAVEFORMS
TESTING BY PRESSURE MACHINES 119
G DATA, SPECIFICATION AND THE WAVEFORMS
TESTING BY SIMULATION LOADS 124
CHAPTER I
INTRODUCTION
1.1 Starting of Induction Motor
In a three phase induction motor, the induced e.m.f. in the rotor circuit depends
on the slip of the induction motor and the magnitude of the rotor current depends upon
this induced e.m.f.[l][2], When the motor is started, the slip is equal to one as the rotor
speed is zero, so the induced e.m.f. in the rotor is large. As a result, a very high current
flows through the rotor. When an induction motor starts, a very high current is drawn by
the stator, on the order of 5 to 9 times the full load current. This high current can
damage the motor windings and because it causes heavy line voltage drop, other
appliances connected to the same line may be affected by the voltage fluctuation. To
avoid such effects, the starting current should be limited. A starter is a device which
limits the starting current by providing reduced voltage to the motor. [3] Once the rotor
speed increases, the full rated voltage is given to it.
2
1.2 Type of Starter Motor
Basically, they can be divided into two major groups; electromechanical starters
and electronic starters [4], The name electromechanical starters stems from the fact that
they employ electromechanical contactors, relays, resistances and transformers for
offering reduced voltage starting. Under this type of starters, methods such as direct
online starting (DOL), star-delta starting, stator resistance starting and autotransformer
starting are listed. As for the electronic starters, there are the AC voltage controller
(soft) starters and V/F starters (inverter). Choosing the type of motor starter for each
application depends on the motor characteristics, available space, load torque
requirements and overall cost. [5].
1.2.1 D.O.L Starter
A DOL starter connects the motor terminals directly to the power supply. Hence,
the motor is subjected to the full voltage of the power supply. Consequently, high
starting current flows through the motor. This type of starting is suitable for small
motors below 5 hp (3.75 kW). By using this method, there is a high probability of
producing jerk. Reduced-voltage starters are employed with motors above 5 hp.
1.2.2 Star Delta Starter
Star/Delta starters are probably the most common reduced voltage starters in the
50Hz world. They are used in an attempt to reduce the start current applied to the motor